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First Solar Cdte Photovoltaic Technology: Environmental, Health and Safety Assessment Final Reportd October 2013E L

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First Solar Cdte Photovoltaic Technology: Environmental, Health and Safety Assessment Final Reportd October 2013E L Collection: Sustainability First Solar CdTe Photovoltaic Technology: Environmental, Health and Safety Assessment Final ReportD October 2013E L I NFORME PHOTOVOLTAIC SOLAR ENERGY DEPARTMENT NATIONAL RENEWABLE ENERGY CENTRE (CENER) ENERGY AND CLIMATE CHANGE AREA FUNDACIÓN CHILE Document Number: SD - 33 Page 1 of 50 Collection: Sustainability INDEX PAGE 1.- EXECUTIVE SUMMARY ......................................................................................................... 4 1.1.- OBJECT ............................................................................................................................... 4 1.2.- SCOPE ................................................................................................................................. 4 1.3.- METHODOLOGY ................................................................................................................. 4 1.4.- CONCLUSIONS ................................................................................................................... 5 2.- TECHNICAL REPORT ............................................................................................................ 7 2.1.- ANALYSIS OF THE CdTe PROCESS TECHNOLOGY FOR PV MODULES ..................... 8 2.1.1.- RAW MATERIALS AND SUPPLIERS ANALYSIS ............................................. 8 2.1.2.- MANUFACTURING PROCESS ....................................................................... 11 2.1.3.- RECYCLING PROCESS .................................................................................. 13 2.1.4.- ENVIRONMENTAL HEALTH AND SAFETY POLICIES .................................. 15 2.1.5.- ANALYSIS OF THE MANUFACTURING BY-PRODUCTS .............................. 18 2.1.5.1.- Air emissions ........................................................................................... 18 2.1.5.2.- Water emissions ...................................................................................... 19 2.1.5.3.- Other solid wastes ................................................................................... 20 2.1.5.4.- Sustainability ........................................................................................... 20 2.2.- LIFE CYCLE ASPECTS OF FIRST SOLAR’S CdTe PV MODULES ................................ 22 2.2.1.- ENERGY PAYBACK TIME (EPBT) .................................................................. 22 2.2.2.- GREENHOUSE GAS (GHG) EMISSIONS ....................................................... 26 2.2.3.- LIFE CYCLE CADMIUM EMISSIONS .............................................................. 29 2.2.4.- TELLURIUM AVAILABILITY ............................................................................. 32 2.2.5.- WATER USE .................................................................................................... 33 2.2.6.- LAND USE AND BIODIVERSITY ..................................................................... 35 2.2.7.- EXTERNAL COSTS ......................................................................................... 37 2.3.- SAFETY DURING CdTe PV MODULES OPERATION ..................................................... 39 2.3.1.- SAFETY AND RELIABILITY CERTIFICATIONS .............................................. 39 2.3.2.- BREAKAGE ...................................................................................................... 40 2.3.3.- HAZARDOUS CIRCUMSTANCES (FIRE) ....................................................... 41 2.3.4.- SLOW DEGRADATION .................................................................................... 43 2.3.5.- END-OF-LIFE ................................................................................................... 45 3.- APPENDICES ........................................................................................................................ 47 3.1.- CHILEAN SIC & SING ELECTRICITY GRID COMPOSITION .......................................... 47 3.2.- DATA FOR OTHER PV SYSTEMS .................................................................................... 49 3.3.- GHG EMISSIONS RATES FOR DIFFERENT ELECTRICTY SOURCES ......................... 50 Document Number: SD - 33 2 Page 2 of 50 Collection: Sustainability FIGURES INDEX .................................................................................................... PAGE Figure 1 Comparative toxicity between Cd and CdTe ................................................................ 10 Figure 2 Schematic representation of First Solar module architecture ...................................... 12 Figure 3 First Solar’s manufacturing process ............................................................................. 13 Figure 4 First Solar’s module recycling technology version 2 .................................................... 14 3 Figure 5 Perrysburg (U.S.) and Kulim (Malaysia) factories average Cd level (µg/m ) ............... 16 3 Figure 6 Personal exposure sampling (µg/m ) by job function performed quarterly .................. 16 Figure 7 Perrysburg (U.S) factory mean Cd levels in blood and urine compared to OSHA biological limit .............................................................................................................................. 17 Figure 8 Kulim (Malaysia) factory mean Cd levels in blood and urine compared to OSHA biological limit .............................................................................................................................. 17 Figure 9 Wastewater treatment process flow diagram ............................................................... 19 Figure 10 First Solar CdTe module efficiencies roadmap .......................................................... 21 Figure 11 Energy Payback Time [yr] for different PV technologies. Irradiation standardized at 1700 kWh/m2/yr. ......................................................................................................................... 23 Figure 12 Energy Payback Time [yr] for CdTe PV at different locations and irradiations. ......... 26 Figure 13 GHG emissions for different PV technologies. Irradiation standardized at 1700 [kWh/m2/yr]. ................................................................................................................................ 26 Figure 14 GHG emissions [g CO2-eq./kWh] for different PV technologies and irradiations. ..... 28 Figure 15 GHG emissions [g CO2-eq./kWh] for different electricity sources. ............................ 29 Figure 16 Life cycle atmospheric Cd emissions for different electricity generation options, Southern European conditions. ................................................................................................... 31 Figure 17 Life cycle management strategies for tellurium availability. ....................................... 33 Figure 18 Life cycle water withdrawal for different energy generation options ........................... 34 Figure 19 Example of typical breakage pattern of First Solar modules ...................................... 41 Document Number: SD - 33 3 Page 3 of 50 Collection: Sustainability 1.- EXECUTIVE SUMMARY 1.1.- OBJECT The object of the work is to evaluate, from an independent point of view, the environmental, health and safety (EHS) aspects of CdTe-based PV modules regarding process technology and modules working period in the field, in the context of First Solar’s initiation of operations in Chile and South America. The independent peer review undertook in the present work has been performed by CENER and Fundación Chile in a joint project. 1.2.- SCOPE This report analyzes First Solar’s process technology, beginning with the study of the raw materials, the manufacturing and recycling processes, including the analysis of the process routing, the materials modification steps and the in-line safety controls. A study of treatment and disposal of by-products will be carried out. Also, life cycle aspects of First Solar’s CdTe PV technology will be analyzed, including energy payback time, greenhouse gas emissions, atmospheric Cd emissions, tellurium availability, water use, impacts on biodiversity, land use, and external costs. Finally, an evaluation of safety aspects during the CdTe modules working period will be done, taking into account four main aspects: breakage, fire, slow degradation and end-of-life. 1.3.- METHODOLOGY The methodology applied for working out the present report is based on a careful data mining and general search of information. Articles and reports, published by recognized scientists, international agencies and research and development institutions have been used as well as information provided by First Solar on their specific technology and management systems. This information is then compared and subjected to a critical analysis, based on the experience and know-how regarding PV technology existing within the PV Department of CENER and the Energy and Climate Change Area of Fundación Chile. Document Number: SD - 33 4 Page 4 of 50 Collection: Sustainability 1.4.- CONCLUSIONS After having conducted a detailed analysis of the most recent scientific articles and the specific internal information provided by First Solar related to the CdTe technology for the manufacturing of PV modules the drawn conclusions are summarized in the following paragraphs: EH&S aspects of First Solar CdTe process technology • Cadmium is obtained as a by-product of smelting of zinc, lead and copper, therefore, its production does not depend on the PV market demand. First Solar’s PV modules, by converting the Cadmium
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